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Conductor Material:: Aluminium: Hard Drawn Electrolytic Aluminium Rods of E.C. Grade Having Purity Not Less

This document specifies requirements for conductor material composition and testing for power lines. It describes allowable materials for the conductor as aluminum, steel, or zinc, and sets composition limits for steel. Joints are permitted in some wire layers during stranding but must meet standards. Extensive testing is required on the complete conductor, individual strands, and during manufacturing, including tensile strength, stress-strain, torsion, impact resistance, and temperature/humidity cycling. Tests verify dimensions, lay ratios, galvanizing, and material properties meet specifications.

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Piyush Goyal
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61 views3 pages

Conductor Material:: Aluminium: Hard Drawn Electrolytic Aluminium Rods of E.C. Grade Having Purity Not Less

This document specifies requirements for conductor material composition and testing for power lines. It describes allowable materials for the conductor as aluminum, steel, or zinc, and sets composition limits for steel. Joints are permitted in some wire layers during stranding but must meet standards. Extensive testing is required on the complete conductor, individual strands, and during manufacturing, including tensile strength, stress-strain, torsion, impact resistance, and temperature/humidity cycling. Tests verify dimensions, lay ratios, galvanizing, and material properties meet specifications.

Uploaded by

Piyush Goyal
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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Conductor Material:

Aluminium: hard drawn electrolytic aluminium rods of E.C. Grade having purity not less
than 99.5%.
Steel: shall be drawn from High carbon steel wire rods.
Element % Composition
Manganese 0.40 to 1.10
Carbon 0.55 - 0.85 max.
Phosphorus 0.05 max.
Sulphur 0.05 max.
Silicon 0.15 to 0.35

Zinc: zinc used for galvanizing shall be electrolytic High Grade (HG) quality of 99.95% purity. It shall
conform to the requirements of IS: 209 – 1992.

 The steel strand shall be not dip galvanised and shall have a zinc coating of minimum 260
gms/sqm on uncoated wire surface.

Joints:
 For aluminium no joints shall be permitted in the individual wires in the outermost layer of
the finished conductor. However, joints in 12 wire & 18 wire layers of the conductor for
zebra and 12 wire layers for shall be allowed, but the joints shall be made by the cold
pressure butt welding method and shall be such that no two joints are within 15 meters at
each other in the complete stranded conductor. All joints shall be annealed over a distance
of at least 200 mm on each side of the joint.
 No strand joints or strand splice in any length of the completed stranded steel core of the
conductor.

Tests
On complete Conductor
a) DC resistance test on stranded conductor : As per Annexure-A
b) UTS test on stranded conductor: As per Annexure-A
c) Stress- Strain test on stranded conductor and core at room temperature: IEC 1089
f) Stress-strain test on stranded conductor and core at elevated temperature As per Annexure-A
g) High temperature endurance & creep test on stranded conductor: As per Annexure-A
h) Sheaves Test: As per Annexure-A
i) Axial Impact Test: As per Annexure-A
j) Radial Crush Test: As per Annexure-A
k) Torsional Ductility Test: As per Annexure-A
l) Aeolian Vibration Test: As per Annexure-A
m) Temperature Cycle Test: As per Annexure-A

On Conductor Strand/core
a) Heat resistance test on Aluminium Alloy strands or core : As per Annexure-A
b) Bending test on core: As per Annexure-A
c) Compression test on core: As per Annexure-A
d) Coefficient of linear expansion on core: As per Annexure-A

Acceptance Tests
a) Visual and dimensional check on drum : As per Annexure-A
b) Visual check for joints scratches etc. And length measurement of conductor by rewinding
c) Dimensional check on steel core and Aluminium strands
d) Check for lay-ratios of various layers: As per Annexure-A
e) Galvanising test on steel strands: As per Annexure-A
g) Torsion and Elongation tests on steel wire: As per Annexure-A
h) Breaking load test on steel and Aluminium strands
i) Wrap test on steel strands and Aluminium Alloy strands: As per IEC: 888 & IEC: 889
j) Minimum conductivity test on thermal resistant Aluminium Alloy strands: As per IEC: 889
l) Heat resistance test on Aluminium Alloy strands: As per Annexure-A
m) Ageing test on filler (if applicable): As per Annexure-A
n) Minimum conductivity test on aluminium clad core strands: As per Annexure-A
q) Coating Test on Zinc – 5% Al –Misc h metal alloy: As per ASTM Coating (if applicable)
B803/B958
r) Adherence of Coating Test on Zinc – 5%: ASTM Al –Misch metal alloy Coating (if applicable)
B803/B958
Note: All the above tests except (j) shall be carried out on Aluminium /Aluminium Alloy and core
strands after stranding only.
s) DC Resistance measurement
Routine Test
a) Check to ensure that the joints are as per Specification
b) Check that there are no cuts, fins etc., on the strands.
c) Check that drums are as per Specification
d) All acceptance tests as mentioned above to be carried out on 10 % of drums
Test during manufacture:
a) Chemical analysis of zinc used for galvanizing : As per Annexure-A
b) Chemical analysis of Aluminium used for making Aluminium strands
c) Chemical analysis of steel used for making steel strands: As per Annexure-A

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